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Cylinder Block: Installation

Fig 1: Exploded View Of Cylinder Block With Torque Specifications
G02862311Courtesy of SUBARU OF AMERICA, INC.
CAUTION: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
  1. Position crankshaft on the #2 and #4 cylinder block.
  2. Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.

    Fluid packing:  THREE BOND 1215 or equivalent

    CAUTION: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
    Fig 2: Applying Fluid Packing To Mating Surface
    G02862312Courtesy of SUBARU OF AMERICA, INC.
  3. Temporarily tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in figure.
    Fig 3: Tightening Cylinder Block Connecting Bolts In Sequence
    G02862313Courtesy of SUBARU OF AMERICA, INC.
  4. Tighten 10 mm cylinder block connecting bolts in alphabetical sequence.

    Tightening torque:  47 N.m (4.8 kgf-m, 34.7 ft-lb)

    Fig 4: Tightening Cylinder Block Connecting Bolts In Sequence
    G02862314Courtesy of SUBARU OF AMERICA, INC.
  5. Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in figure.

    Tightening torque: 

    1. (A)-(G);  25 N.m (2.5 kgf-m, 18.1 ft-lb)
    2. (H);  6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
    Fig 5: Tightening Cylinder Block Connecting Bolts In Sequence
    G02862315Courtesy of SUBARU OF AMERICA, INC.
  6. Install rear oil seal using ST1 and ST2.

    ST1 499597100:  OIL SEAL GUIDE

    ST2 499587200:  OIL SEAL INSTALLER

    Fig 6: Installing Rear Oil Seal
    G02862316Courtesy of SUBARU OF AMERICA, INC.
  7. Position the top ring gap at (A) or (B) in the figure.
    Fig 7: Positioning Top Ring Gap
    G02862317Courtesy of SUBARU OF AMERICA, INC.
  8. Position the second ring gap at 180° on the reverse side for the top ring gap.
  9. Position the upper rail gap at (C) or (D) in the figure.
    Fig 8: Positioning Upper Rail Gap
    G02862318Courtesy of SUBARU OF AMERICA, INC.
  10. Position the expander gap at 180° of the reverse side for the upper rail gap.
  11. Position the lower rail gap at (E) or (F) in the figure.
    CAUTION:
    • Ensure ring gaps do not face the same direction.
    • Ensure ring gaps are not within the piston skirt area.
    Fig 9: Positioning Lower Rail Gap
    G02862319Courtesy of SUBARU OF AMERICA, INC.
  12. Install circlip.

    Install circlips in piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

    CAUTION: Use new circlips.
    Fig 10: Installing Circlip
    G02862320Courtesy of SUBARU OF AMERICA, INC.
    CAUTION: Piston front mark faces towards the front of the engine.
    Fig 11: Identifying Piston Front Mark
    G02862321Courtesy of SUBARU OF AMERICA, INC.
    Fig 12: Exploded View Of Cylinder Block And Components With Torque Specifications
    G02862322Courtesy of SUBARU OF AMERICA, INC.
  13. Installing piston
    1. Turn cylinder block so that #1 and #2 cylinders face upward.
    2. Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead center.

      ST1 499987500:  CRANKSHAFT SOCKET

    3. Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2.

      ST2 498747100:  PISTON GUIDE

    Fig 13: Installing Pistons
    G02862323Courtesy of SUBARU OF AMERICA, INC.
  14. Installing piston pin
    1. Insert ST3 into service hole to align piston pin hole with connecting rod small end.
      CAUTION: Apply a coat of engine oil to ST3 before insertion.

      ST3 499017100:  PISTON PIN GUIDE

      Fig 14: Inserting Piston Pin Guide Into Service Hole
      G02862324Courtesy of SUBARU OF AMERICA, INC.
    2. Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole.
    3. Install circlip.
      CAUTION: Use new circlips.
      Fig 15: Installing Circlip
      G02862325Courtesy of SUBARU OF AMERICA, INC.
    4. Apply fluid packing around the service hole plug.

      Fluid packing:  THREE BOND 1215 or equivalent

      Fig 16: Applying Fluid Packing Around Service Hole Plug
      G02862326Courtesy of SUBARU OF AMERICA, INC.
    5. Install service hole plug and gasket.
      CAUTION: Use a new gasket.
      Fig 17: Installing Service Hole Plug And Gasket
      G02862327Courtesy of SUBARU OF AMERICA, INC.
      Fig 18: Exploded View Of Cylinder Block And Components With Torque Specifications
      G02862328Courtesy of SUBARU OF AMERICA, INC.
    6. Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.
  15. Install water pipe.
    Fig 19: Installing Water Pipe
    G02862329Courtesy of SUBARU OF AMERICA, INC.
  16. Install baffle plate.

    Tightening torque:  6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

  17. Install oil strainer and O-ring

    Tightening torque:  10 N.m (1.0 kgf-m, 7 ft-lb)

  18. Install oil strainer stay.
  19. Apply fluid packing to matching surfaces and install oil pan.

    Fluid packing:  THREE BOND 1215 or equivalent

    Fig 20: Applying Fluid Packing To Oil Pan Matching Surfaces
    G02862330Courtesy of SUBARU OF AMERICA, INC.
  20. Apply fluid packing to matching surfaces and install oil separator cover.

    Fluid packing:  THREE BOND 1215 or equivalent

    Fig 21: Applying Fluid Packing To Oil Separator Cover Matching Surfaces
    G02862331Courtesy of SUBARU OF AMERICA, INC.
  21. Install flywheel or drive plate.

    To lock crankshaft, use ST.

    ST 498497100:  CRANKSHAFT STOPPER

    Tightening torque:  72 N.m (7.3 kgf-m, 52.8 ft-lb)

    • MT MODEL
      Fig 22: Locking Crankshaft (MT Model)
      G02862332Courtesy of SUBARU OF AMERICA, INC.
    • AT MODEL
    Fig 23: Locking Crankshaft (AT Model)
    G02862333Courtesy of SUBARU OF AMERICA, INC.
  22. Install housing cover.
  23. Installation of oil pump.
    1. Discard front oil seal after removal. Replace with a new one using ST.

      ST 499587100:  OIL SEAL INSTALLER

      Fig 24: Installing Front Oil Seal
      G02862334Courtesy of SUBARU OF AMERICA, INC.
    2. Apply fluid packing to matching surface of oil pump.

      Fluid packing:  THREE BOND 1215 or equivalent

      Fig 25: Applying Fluid Packing To Matching Surface Of Oil Pump
      G02862335Courtesy of SUBARU OF AMERICA, INC.
    3. Apply a coat of engine oil to the inside of the oil seal.
      Fig 26: Applying Coat Of Engine Oil To Inside Of Oil Seal
      G02862336Courtesy of SUBARU OF AMERICA, INC.
    4. Install oil pump on cylinder block. Be careful not to damage oil seal during installation.

    Tightening torque:  6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

    CAUTION:
    • Do not forget to install O-ring and seal when installing oil pump.
    • Align flat surface of oil pump's inner rotor with crankshaft before installation.
  24. Install water pump and gasket.

    Tightening torque: 

    1. First;  12 N.m (1.2 kgf-m, 8.7 ft-lb)
    2. Second;  12 N.m (1.2 kgf-m, 8.7 ft-lb)
    CAUTION:
    • Be sure to use a new gasket.
    • When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
    Fig 27: Tightening Bolts In Sequence
    G02862337Courtesy of SUBARU OF AMERICA, INC.
  25. Install water by-pass pipe for heater.
  26. Install oil cooler. (AT vehicles only)

    Tightening torque: 

    1. T1;  55 N.m (5.6 kgf-m, 41 ft-lb)
    2. T2;  69 N.m (7.0 kgf-m, 50.6 ft-lb)
    Fig 28: Installing Oil Cooler
    G02862338Courtesy of SUBARU OF AMERICA, INC.
  27. Install oil filter using ST.

    ST 498547000:  OIL FILTER WRENCH

  28. Install water by-pass pipe between oil cooler and water pump. (AT vehicles only)
    Fig 29: Installing Water By-Pass Pipe Between Oil Cooler And Water Pump
    G02862339Courtesy of SUBARU OF AMERICA, INC.
  29. Tighten cylinder head bolts.
    1. Apply a coat of engine oil to washers and bolt threads.
    2. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence.

      Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.

    3. Back off all bolts by 180° first; back them off by 180° again.
    4. Tighten bolts (a) and (b) to 34 N.m (3.5 kgf-m, 25 ft-lb).
    5. Tighten bolts (c), (d), (e) and (f) to 15 N.m (1.5 kgf-m, 11 ft-lb).
    6. Tighten all bolts by 80-90° in alphabetical sequence.
      CAUTION: Do not tighten bolts more than 90°.
    7. Further tighten all bolts by 80-90° in alphabetical sequence.
    CAUTION: Ensure that the total "re-tightening angle" (in the former two steps), do not exceed 180°.
    Fig 30: Tightening Bolts In Sequence
    G02862340Courtesy of SUBARU OF AMERICA, INC.
  30. Install oil level gauge guide and tighten attaching bolt (left side only).
  31. Install rocker cover.
  32. Install crankshaft sprocket. Refer to INSTALLATION under CAMSHAFT SPROCKET .
  33. Install camshaft sprocket. Refer to INSTALLATION under CAMSHAFT SPROCKET .
  34. Install timing belt assembly. Refer to INSTALLATION under TIMING BELT ASSEMBLY .
  35. Install belt cover. Refer to INSTALLATION under BELT COVER .
  36. Install crankshaft pulley. Refer to INSTALLATION under CRANKSHAFT PULLEY .
  37. Install generator and A/C compressor brackets on cylinder head.
  38. Install V-belt. Refer to INSTALLATION under V-BELT .
  39. Install intake manifold. Refer to INSTALLATION under INTAKE MANIFOLD .
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